Cutting foam is pretty tricky without a hot wire cutter. Don’t have one ... He designed the frame in SketchUp and cut it out with his CNC router, although a saw will work just as well for ...

What you really need is a hot wire for nice clean cuts. [Elite Worm] built a hot wire foam ... cutter is pretty versatile, but you could go even smaller with a handheld version, or build a larger ...